Ddl-8000A Instruction Manual Contents

DDL-8000A INSTRUCTION MANUAL CONTENTS

1. SPECIFICATIONS...... 1 1-1. Specifications of the sewing machine head...... 1 1-2. Specifications of the control box...... 1 2. SET UP...... 2 2-1. Drawing of table...... 2 2-2. Cautions when setting up the sewing machine...... 3 2-2-1. How to carry the sewing machine...... 3 2-2-2. Caution when placing the sewing machine...... 3 2-3. Installation...... 3 2-4. Installing the pedal sensor...... 4 2-5. Connecting the connector...... 5 2-6. Installing the power switch (for CE)...... 6 2-7. Installing the reactor box...... 7 2-8. How to install the power plug...... 8 2-9. Installing the thread stand...... 9 2-10. Attaching the connecting rod...... 9 2-11. Adjustment of the pedal...... 10 2-11-1. Installing the connecting rod...... 10 2-11-2. Adjusting the pedal angle...... 10 2-12. Pedal operation...... 10 2-13. Power switch...... 11 2-14. Lubrication...... 12 3. PREPARATION BEFORE SEWING...... 13 3-1. Attaching the needle...... 13 3-2. Removing/fitting the bobbin case...... 13 3-3. Winding the bobbin thread...... 14 3-4. Threading the machine head...... 15 3-5. Thread tension...... 15 3-5-1. Adjusting the needle thread tension...... 15 3-5-2. Adjusting the bobbin thread tension...... 15 3-6. Presser foot pressure...... 16 3-7. Adjusting the stitch length...... 16 3-8. Changing the sewing speed...... 17 3-9. LED hand light...... 18 3-10. Reverse feed stitching...... 18 3-11. Adjusting the amount of oil (oil splashes) in the hook...... 19 3-11-1. Adjusting the amount of oil in the hook...... 19 3-11-2. How to confirm the amount of oil (oil splashes)...... 20 3-11-3. Sample showing the appropriate amount of oil...... 20 3-12. Adjusting the thread take-up spring and the thread take-up stroke...... 21 4. FOR THE OPERATOR...... 22 4-1. How to set the machine head and to initialize data (the factory-set state at the time of shipment)...... 22

i 4-2. Operation panel...... 23 4-3. Audio guidance...... 25 4-4. Setting the clock...... 26 4-5. Operating procedure of the sewing pattern...... 27 4-5-1. Reverse feed stitching pattern...... 27 4-5-2. Overlapped stitching pattern...... 28 4-5-3. Polygonal-shape stitching pattern...... 29 4-6. Function setting...... 31 4-7. Setting the function keys (F1 and F2)...... 32 4-8. Production support function...... 33 4-8-1. How to set the production support parameters...... 33 4-8-2. List of production support parameters...... 34 4-8-3. How to display the operation rate of the sewing machine...... 35 4-8-4. How to display the number of pieces produced...... 36 4-9. Function setting list...... 37 4-10. Detailed explanation of selection of functions...... 42 4-11. How to use the bobbin counter...... 48 4-12. Initialization of function setting data...... 49 4-13. Password lock...... 50 4-14. About the USB...... 51 5. ADJUSTMENT OF THE MACHINE HEAD (APPLICATION)...... 52 5-1. Needle-to-hook relationship...... 52 5-2. Adjusting the needle thread presser device...... 53 5-3. Adjusting the thread trimmer...... 56 5-3-1. For checking of the thread trimming cam timing...... 56 5-3-2. Adjustment of the thread trimming cam timing...... 56 5-3-3. Checking of the knife unit...... 57 5-3-4. Adjustment of the knife unit...... 58 5-4. Adjusting the main shaft stop position...... 59 5-5. Grease shortage warning...... 60 5-5-1. Grease shortage warning...... 60 5-5-2. Grease shortage error...... 60 5-5-3. How to reset the grease shortage error...... 61 5-6. Disposal of batteries...... 62 6. CARE...... 63 6-1. Cleaning...... 63 6-2. Applying grease...... 64 6-3. Applying grease to the needle bar lower bushing...... 64 7. LIST OF ERROR CODES...... 65

ii 1. SPECIFICATIONS

1-1. Specifications of the sewing machine head DDL-8000A-P - B Face plate portion lubricating method M Semi-dry S Micro-quantity lubrication Seam specification S Medium-weight materials H Heavy-weight materials Needle thread nipper specification N With 0 Without

DDL-8000A-PMS DDL-8000A-PSH 5,000 sti/min (P = Less than 4) 4,500 sti/min (P = Less than 4) Max. sewing speed 4,000 sti/min for "P= 4 or more" 4,000 sti/min for "P= 4 or more" Stitch length 5 mm Hand lifter 5.5 mm Presser foot lift Auto lifter 13 mm or more Audio guidance Provided 1738 Nm65 to 110 (DB × 1 #9 to 18) 1738 Nm125 to 160 (DB × 1 #20 to 23) Needle *1 134 Nm65 to 110 (DP × 5 #9 to 18) 134 Nm125 to 160 (DP × 5 #20 to 23) Lubricating oil JUKI NEW DEFRIX OIL No. 1 or JUKI CORPORATION GENUINE OIL 7 Motor AC servo motor PMS ; - Equivalent continuous emission sound pressure level (LpA) at the workstation: A-weighted value of 78.7 dBA ; (Includes KpA = 2.5 dBA) ; according to ISO 10821- C.6.2 -ISO 11204 GR2 at 4,000 sti/min. Noise PSH ; - Equivalent continuous emission sound pressure level (LpA) at the workstation: A-weighted value of 82.0 dBA ; (Includes KpA = 2.5 dBA) ; according to ISO 10821- C.6.2 -ISO 11204 GR2 at 4,000 sti/min.

• The sewing speed will vary depending on the sewing conditions. The sewing speed preset at the time of shipping is 4,000 sti/min. *1 : Needle used depends on the destination.

1-2. Specifications of the control box

Supply Single phase 3-phase Single phase voltage 200 to 240V 200 to 240V 220 to 240V CE Frequency 50Hz/60Hz 50Hz/60Hz 50Hz/60Hz Temperature : 0 to 35˚C Temperature : 0 to 35˚C Temperature : 0 to 35˚C Operating environment Humidity : 90% or less Humidity : 90% or less Humidity : 90% or less Input 330VA 330VA 170VA

– 1 – 2. SET UP 2-1. Drawing of table

0 0 +0.5 +0.5

1 ±0.5

20 21

S-S

40°

1.2

±0.5 R2 40° R2

Y-Y

±0.5 10 R2 X-X

1.2 R2 reference U-U reference

R2 14 Rubber cushion Rubber cushion Y-Y部ｺﾞﾑ取付参考図

X-X部ｺﾞﾑ取付参考図 installing drawing for

535

installing drawing for

360

141 139 190

43 86.5 55 17

21.5 27.5

±0.5

40 50 40

W R30 84 21.5 18

R30 R2 ∅16 R2 R8 9 R8 ∅26 18 R6 Q-Q

50 50 R8 S 52 S 14

52.5

75 10

1 R27.5 ± 32

R242.5 R242.5 ±1 C D （138.5）

154.6

60 R8 30 Ｙ 2×Ｒ10 115 90 195

240 E Ｒ18 30

Ｚ I 297

R22.5 R20 C1 Ｙ

±0.5 R27.5

T-T R10 R8 68.5 R22.5 Ｚ G F H 80

X R10 X 19.5 ±0.5

Q 29

Q 140 Z-Z（２ヵ所） (2 locations) ±1

279

23.5 ±0.5 T T

520 29 (2 locations)

Y-Y（２ヵ所）

R10

17.5 ±0.5 810 80 R10 X X X-X(2ヵ所） (2 locations) （172.5） 1200

Y R22.5 R22.5

Z Ｃ1

Ｒ2 80 27

R20 Y

Ｒ20 R18 Ｒ20

U U Z

R30 R30

136 22.5 (22.5) 40°

181 110 -1 (244) 0 (Drill a hole at the time of set-up.) (Drill a hole at the time of set-up.) (Drill a hole at the (591)

（525.4）（15） B

bottom surface, depth 20 bottom surface, depth 10 (hinge side only) on the on the 100

W-W

R30 R6 R2 ø13 drilled hole

R2 ×

（6） R30 4×ø3.4 Installing position of drawer stopper (on the reverse side) ø17 drilled hole 3 2×ø3.5, depth 10 2×ø3.5, depth 10 2×ø3.4 Through hole C1.5 to C2.5

390 A B C D E F G H I

– 2 – 2-2. Cautions when setting up the sewing machine Thank you very much for the purchase of JUKI Industrial Sewing Machine this time. Make sure of items 2-1 through 2-14 before operating to use this sewing machine with ease.

2-2-1. How to carry the sewing machine Carry the sewing machine while holding the machine arm with two persons as shown in the figure.

1. Never hold the handwheel since it rotates. 2. Be sure to handle the sewing machine with two persons or more since the sewing machine weighs 40 kg or more.

2-2-2. Caution when placing the sewing machine Place the sewing machine on a horizontal and plane place when placing it and do not place any protrud- ing thing such as a screwdriver or the like. ×

2-3. Installation 1) The under cover ❹ should rest on the four cor- ❺ ners of the machine table groove. Mount rubber hinge seat ❺ on the table and fix it on the table ❸ ❸ with a nail. 2) Fix two rubber seats ❶ on side A (operator’s ❶ ❶ side) using nails ❷ as illustrated above. Fix two cushion seats ❸ on side B (hinged side) using a

1.2 ± 0.5 mm rubber-based adhesive. Then place under cover ❹ on the fixed seats.

1 ± 0.5 mm 3) Fit hinge ❼ into the opening in the machine bed,

1.2 ± 0.5 mm and fit the machine head to table rubber hinge seat ❺ before placing the machine head on cush- 23.5 mm ❶ 19.5 mm ions ❻ on the four corners. ❹

❷ ❸ Do not hold the handwheel.

A B

❻

❹ ❼

– 3 – 4) Securely attach head support rod ❹ to the table until it goes no further.

Be sure to mount the machine head support rod ❹ on the machine table so that its height from the table surface becomes 56 to 60 mm.

❹

2-4. Installing the pedal sensor 1) Install the pedal sensor to the table with mounting screws ❶ supplied with the unit. It is necessary to install the pedal sensor at such a position that the connecting rod is perpendicular to the table. 2) After the completion of installation of the pedal sensor on the table, place the sewing machine head on the table. ❶

– 4 – 2-5. Connecting the connector

WARNING : • To protect against personal injury resulting from abrupt start of the sewing machine, be sure to turn the power OFF, unplug the machine and wait for five minutes or more before installing the pedal sensor. • To prevent damage of device caused by maloperation and wrong specifications, be sure to connect all the corresponding connectors to the specified places. (If any of the connectors is inserted into a wrong connector, not only the device corresponding to the connector can break but also it can start abruptly, inviting the risk of personal injury.) • To prevent personal injury caused by maloperation, be sure to lock the connector with lock. • Do not connect the power plug until the connection of cords is completed. • Fix the cords while taking care not to forcibly bend them or excessively clamp them with staples. • As for the details of handling respective devices, read carefully the Instruction Manuals supplied with the devices before handling the devices.

1. Do not insert the power plug into the wall outlet. 2. Check to be sure that the power switch is turned OFF. 3. Be sure to fully insert the connectors into the corresponding ports until they are locked.

1) Draw out pedal sensor cable ❶ and AC input ❶ cable ❷ coming from the electrical box to the undersurface of the sewing machine table through cable draw-out hole ❸ . ❷ ❸

2) Connect pedal sensor cable ❶ and the connector under the table. ❶

3) Secure pedal sensor cable ❶ and AC Underside of the table input cable ❷ with staples ❹ . [EU-type models] Install ring core ❺ . For one ring core ❺ , clamp the pedal sensor cable ❶ after winding the cable Pedal sensor Slack ❸ round the torus of the ring core three times. ❹ ❹ ❶

❺ Eu-type ❹ ❷

– 5 – 2-6. Installing the power switch (for CE)

WARNING : 1. Be sure to attach the ground wire (green/yellow) to the specified location (on the ground side). 2. Take care not to allow terminals to come in contact with each other. 3. When closing the power switch cover, take care not to allow the cord to be caught under it.

Do not insert the power plug into the plug receptacle. ❶ 1) Remove screw ❶ on the side face of the power switch cover to open the power switch cover.

2) Pass AC input cord ❷ , ❸ through the rear face of ❹ the power switch. Bundle the cord with cable clip band ❹ to secure it.

❷

1ø 220V-240V 3) Securely fix the terminals of the AC input cord ❷ , Blue Blue ❸ by tightening the screws at the specified locations. 4) Close the power switch cover. Tighten screw ❶ on the side face of the power switch cover.

Green/ ❷ Yellow Green/ ❸ Yellow Brown Brown

– 6 – 2-7. Installing the reactor box

* For the EU-type models, install the reactor box that is supplied with the sewing machine.

❸ 1) Connect the terminals of power cord ❶ of the ❷ ❹ electrical box to reactor-box PCB asm. ❷ and to reactor box mounting plate ❸ . Connect brown wire to the first connector A A and blue wire B to the third connector respec- C tively from the top of terminal block on the B reactor box PCB asm. using screws. Connect ❻ green/yellow wire C to reactor box mounting plate ❸ with earth setscrew ❹ . ❺ ❶ 2) Attach cable clip ❺ to the power cord of electrical box. Attach the power cord together with the cable clip to reactor box mounting plate ❸ ❸ ❽ with cable clip setscrew ❻ . 3) Attach cord bushes ❽ to input/output cables ❽ ❼ ❶ and ❼ of the reactor box. Attach both bushes in the same manner. 4) Attach reactor box cover to reactor box mounting plate ❸ with four reactor-box cover ❽ setscrews ❾ . ❶ ❾ At this time, fix cord bushes❽ attached to input/output cables ❶ and ❼ in the concave section on reactor box cover to eliminate a ❾ gap between reactor box and cover .

5) Install reactor box on the table stand with four accessory wood screws . Adjust the installing position according to the size of table stand so that the reactor ❼ box does not protrude from the edge of table stand.

Operator's side 6) Install accessory ring cores . Undersurface of table For two ring cores , clamp the power cord of the electrical box after winding the cable Power box round the torus of the ring core twice. 7) Fix input/output cables ❶ and ❼ of reactor box on the table stand using accessory ❼ ❶ cord staple . At this time, take care not to cross the input- and output-cables.

– 7 – 2-8. How to install the power plug

WARNING : 1. Be sure to attach the ground wire (green/yellow) to the specified location (on the ground side). 2. Take care not to allow terminals to come in contact with each other.

1) Connect the power cord to power plug ❶ . Con- 1ø 200-240V nect the blue and brown wires (1ø) to the power Blue AC 200-240V supply side and the green/yellow wire to the earth Brown side as illustrated in the figure. Green / Yellow (ground wire) 1. Be sure to prepare the power plug ❶ which conforms to the safety standard. 2. Be sure to connect the ground lead (green/yellow) to the grounding side. 2) Check that the power switch is in the OFF state. Then, insert the power plug ❶ coming from the power switch into the plug receptacle.

❶ In prior to the connection of the power plug ❶ , re-check the supply voltage specification indicated on the control box.

* The power plug ❶ is different in shape according to the destination of the sewing machine.

– 8 – 2-9. Installing the thread stand 1) Assemble the thread stand unit, and insert it in the hole in the machine table. 2) Tighten nut ❶ .

❶

2-10. Attaching the connecting rod

WARNING : To protect against possible personal injury due to abrupt start of the machine, be sure to start the following work after turning the power off and a lapse of 5 minutes or more.

Fix connecting rod ❶ to installing hole of pedal lever ❸ ❹ ❸ ❷ with nut ❸ .

❶

❷

– 9 – 2-11. Adjustment of the pedal WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

2-11-1. Installing the connecting rod 1) Move pedal ❸ to the right or left as illustrated by the arrows so that motor control lever ❶ and con- ❹ necting rod ❷ are straightened. ❷ ❶ 2-11-2. Adjusting the pedal angle ❹ 1) The pedal tilt can be freely adjusted by changing ❷ the length of the connecting rod ❷ . 2) Loosen adjust screw ❹ , and adjust the length of connecting rod ❷ .

❸

2-12. Pedal operation The pedal is operated in the following four steps : 1) The machine runs at low sewing speed when you A lightly depress the front part of the pedal. B 2) The machine runs at high sewing speed when B you further depress the front part of the pedal. A (If the automatic reverse feed stitching has been C preset, the machine runs at high speed after it (Neutral completes reverse feed stitching.) position) 3) The machine stops (with its needle up or down) D when you reset the pedal to its original position. C E 4) The machine trims threads when you fully depress the back part of the pedal. E

The presser foot goes up when you lightly depress the back part of the pedal D, and if you further depress the back part, the thread trimmer is actuated. When starting sewing from the state that the presser foot has been lifted with the Auto-lifter and you depress the back part of the pedal, the presser foot only comes down. • If you reset the pedal to its neutral position C during the automatic reverse feed stitching at seam start, the machine stops after it completes the reverse feed stitching. • The machine will perform normal thread trimming even if you depress the back part of the pedal immediately following high or low speed sewing. • The machine will completely perform thread trimming even if you reset the pedal to its neutral position C immediately after the machine started thread trimming action. 5) When you depress lightly the back part of pedal at its neutral position C before starting, the pedal is brought to the first presser lifting position D. When you depress the back part of pedal further, the pedal is brought to the second presser lifting position E.

– 10 – 2-13. Power switch

1) Lightly press the power switch ❶ by hand to turn the power ON. Power switch ❶ is in the ON state when the "I" mark side is pressed. It is in the OFF state when the "○" side is pressed.

1. Do not strongly tap the power switch by hand. 2. If the power indicator LED on the ❶ panel does not light up after having turned ON the power switch ❶ , immediately turn OFF the power switch ❶ and check the supply voltage. When you want to re-turn ON power switch ❶ after carrying out the aforementioned steps, it is necessary to wait for five minutes or more after you have turned OFF power switch ❶. 3. Do not place your hand or anything under the needle since the needle bar may automatically move according to the memory switch setting when you turn ON the power to the sewing machine.

2) When you depress the back part of pedal, the needle bar and the presser lifting motor carry out their initial operation to allow the sewing machine to start sewing.

If you attempt to start sewing without depressing the back part of pedal, the warning message screen shown below will be displayed. To prevent this, be sure to start sewing after depressing the back part of pedal.

< Origin retrieval screen >

– 11 – 2-14. Lubrication

WARNING : 1. Do not connect the power plug until the lubrication has been completed so as to prevent accidents due to abrupt start of the sewing machine. 2. To prevent the occurrence of an inflammation or rash, immediately wash the related portions if oil adheres to your eyes or other parts of your body. 3. In the case of adding oil to the sewing machine while it is energized, do not place your hands into the moving parts for the sake of safety.

Fill the oil tank with oil for hook lubrication before operating the sewing machine. 1) Turn ON the power switch. Remove oil hole cap ❶ . Pour NEW Defrix Oil No. 1 (part number: ❶ 40214221 or MDFRX16000C0) supplied with the unit or JUKI CORPORATION GENUINE OIL 7 (part number: 40102087) into the oil tank through the oil hole. 2) When the oil amount in the oil tank reaches the maximum amount, flashes on and off on the

operation panel and the voice warning is given. Stop oiling. If the oil is filled excessively, it will leak from the air vent hole in the oil tank or proper lubrication will be not performed. In addition, when the oil is vigorously filled, it may overflow from the oil hole. So, be careful. 3) When the remaining amount of oil in the oil tank has reduced, flashes on and off on the operation panel

and the voice warning is given.

Refill the oil tank with oil.

1. When you use a new sewing machine or a sewing machine after an extended period of dis- use, use the sewing machine after performing break-in at 2,000 sti/min or less. 2. For the oil for hook lubrication, purchase JUKI NEW DEFRIX OIL No. 1 (part number : MD- FRX1600C0) or JUKI CORPORATION GENUINE OIL 7 (part number : 40102087). 3. Be sure to lubricate clean oil. 4. Do not operate the machine with the oil hole cap ❶ removed. Never remove cap ❶ from the oil inlet in any case other than oiling. In addition, take care not to lose it.

– 12 – 3. PREPARATION BEFORE SEWING 3-1. Attaching the needle

WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

Use the specified needle for the machine. Use the proper needle in accordance with the thickness of D B thread used and the kinds of the materials. 1) Turn the handwheel until the needle bar reaches ❷ A the highest point of its stroke. ❶ C 2) Loosen screw ❷ , and hold needle ❶ with its indented part A facing exactly to the right in direction B. 3) Insert the needle fully into the hole in the needle bar in the direction of the arrow until the end of hole is reached. 4) Securely tighten screw ❷ . 5) Check that long groove C of the needle is facing exactly to the left in direction D.

3-2. Removing/fitting the bobbin case

WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

1) Turn the handwheel to lift the needle above the throat plate. 2) Install the bobbin in the bobbin case so that the thread wound direction is clockwise. 3) Pass the thread through thread slit A of the bobbin case, and pull the thread in direction C. By A so doing, the thread will pass under the tension spring and come out from notch B. 4) Check that the bobbin rotates in the direction of the arrow when thread is pulled. B 5) Pinching latch D of the bobbin case with fingers, fit the bobbin case in the hook.

– 13 – 3-3. Winding the bobbin thread

❽ 1) Insert the bobbin deep into the bobbin winder spindle ❶ until it will go no further. 2) Pass the bobbin thread pulled out from the spool rested on the right side of the thread stand following the order as shown in the figure on the left. Then, wind clockwise the end of the bobbin thread on the bobbin several times. 3) Press the bobbin winding lever ❷ in the direction A of A and start the sewing machine. The bobbin ❷ ❶ rotates in the direction of B and the bobbin thread ❸ ❶ D is wound up. The bobbin winder spindle automatically as soon as the winding is finished. B 4) Remove the bobbin and cut the bobbin thread C with the thread cut retainer ❸ . ❹ 5) When adjusting the winding amount of the bobbin thread, loosen setscrew ❹ and move bobbin winding lever ❷ to the direction of C or D. Then ❻ tighten setscrew ❹ . ❼ To the direction of C : Decrease E To the direction of D : Increase ❻ 6) In case that the bobbin thread is not wound evenly on the bobbin, remove the handwheel, loosen F ❺ screw ❺ and adjust the height of bobbin thread tension ❽ . ❻

• It is the standard that the center of the bobbin is as high as the center of thread tension disk ❻ . • Adjust the position of thread tension disk ❻ to the direction of E when the winding amount of the bobbin thread on the lower part of the bobbin is excessive and to the direction F when the winding amount of the bobbin thread on the upper part of the bobbin is excessive. After the adjustment, tighten screw ❺ . 7) To adjust the tension of the bobbin winder, turn the thread tension nut ❼ .

1. When winding the bobbin thread, start the winding in the state that the thread between the bobbin and thread tension disk ❻ is tense. 2. When winding the bobbin thread in the state that sewing is not performed, remove the needle thread from the thread path of thread take-up and remove the bobbin from the hook. 3. There is the possibility that the thread pulled out from the thread stand is loosened due to the influence (direction) of the wind and may be entangled in the handwheel. Be careful of the direction of the wind.

– 14 – 3-4. Threading the machine head

WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

[NB type] [0B type] ❶

❸

❾ ❷

(Note) ❹ (Note) Be sure to pass the thread Do not pass this thread A through the section B. ❽ through section . ❻ [S type] [H type] ❺

❼

3-5. Thread tension

B A ❶ E F ❸

❷

D C

3-5-1. Adjusting the needle thread tension 3-5-2. Adjusting the bobbin thread tension 1) Turn thread tension No. 1 nut ❶ clockwise (in di- 1) Turn tension adjusting screw ❸ clockwise (in rection A), to shorten the thread length remaining direction E) to increase or counterclockwise (in on the needle after thread trimming or counter- direction F) to reduce the bobbin thread tension. clockwise (in direction B), to lengthen the thread length. 2) Turn thread tension nut ❷ clockwise (in direction C) to increase or counterclockwise (in direction D) to reduce the needle thread tension.

– 15 – 3-6. Presser foot pressure

WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

1) Loosen nut ❷ . As you turn presser spring regula- B A tor ❶ clockwise (in direction A), the presser foot ❶ pressure will be increased. C ❷ 2) As you turn the presser spring regulator ❶ counter-clockwise (in direction B), the pressure will be decreased. 3) After adjustment, tighten nut ❷ .

The standard value of the height C of presser spring regulator ❶ is as follows : • S type : 31.5 to 29 mm (approx. 40 to 45 N / 4 to 4.5 kg) • H type : 31.5 to 28 mm (approx. 50 to 60 N / 5 to 6 kg)

To avoid personal injury, never put your fingers under the presser foot.

3-7. Adjusting the stitch length * The dial calibration is in millimeters. A B 1) Turn stitch length dial ❶ in the direction of the arrow, and align the desired number to marker dot ❶ A on the machine arm. 2) To change over the feed scale mark from "large" to "small", turn stitch dial ❶ while pressing feed ❸ ❷ lever ❷ in the direction of the arrow and pressing stopper ❸ in the direction of arrow B (toward the back of the arm). 3) To change over the feed scale mark from "small" to "large", turn stitch dial ❶ while pressing stopper ❸ in the direction of arrow B (toward the back of the arm). 4) Release stopper ❸ to fix stitch dial ❶ .

– 16 – 3-8. Changing the sewing speed

The sewing speed can be changed with ❻ on the normal sewing screen.

❻

[How to change the sewing speed] 1) The sewing speed change screen is dis-

played by pressing ❻ on the

normal sewing screen. On the sewing speed change screen, the sewing speed can be changed.

2) Press ❽ to determine the set val-

ue. Then, the sewing machine returns to the normal sewing state.

❽

– 17 – 3-9. LED hand light

WARNING : In order to protect against personal injury due to unexpected start of the sewing machine, never bring hands near the needle entry area or place foot on the pedal during the adjustment of intensity of the LED.

* This LED is intended to improve operability of the sewing machine and is not intended for maintenance.

The sewing machine is provided as standard with an LED light which illuminates the needle entry area. Intensity adjustment and turn-off of the light is carried out by pressing switch ❶ . Every time the switch is pressed, the light is adjusted in intensity in five steps ❶ and is turned off in turn. [Change of intensity] 1 ⇒ ...... 4 ⇒ 5 ⇒ 1 Bright ⇒ ...... Dim ⇒ Off ⇒ Bright

In this way, every time the switch ❶ is pressed, the hand lamp status is changed in repetition.

3-10. Reverse feed stitching [One-touch type reverse feed stitching mecha- nism] ❶ ❸ The one-touch type reverse feed switch is pressed, the machine performs reverse feed stitch- ❶ ing. ❶ The machine resumes normal feed stitching the moment the switch lever is released.

[Reverse feed stitching by means of the reverse (Fig. 1) feed lever] Length of the seam sewn by feeding the material in the normal or reverse direction of feed can be con- trolled by operating reverse feed lever ❷ .

[Adjusting the position of one-touch type reverse feed switch] One-touch type reverse feed switch ❶ can be used at two different positions by turning it. (Fig. 1)

❷ [Needle up/down switch] The needle can be moved up and down to change the needle position by a half stitch by pressing needle up/down switch ❸ . (The function of this switch can be changed to 1-stitch correction, etc. by carrying out the procedure described in "4-6. Function setting" p. 31 .)

– 18 – 3-11. Adjusting the amount of oil (oil splashes) in the hook

WARNING : Be extremely careful about the operation of the machine since the amount of oil has to be checked by turning the hook at a high speed.

3-11-1. Adjusting the amount of oil in the hook

❹

❷ ❸

❶

Decrease Increase

Tighten (turn clockwise) oil amount adjustment screw ❶ to increase the amount of oil in the hook, or loosen (turn counterclockwise) to decrease it.

[When using RP hook (hook for dry head) for DDL-8000A-PMS type] 1. Remove hook driving shaft oil wick setscrew ❷ and attach hook driving shaft stopper screw ❸ (part number : 11079506) and rubber ring ❹ (part number : RO036080200). 2. Loosen oil amount adjustment screw ❶ up to the minimum so as to reduce the oil amount in the hook. However, do not completely stop the oil and be careful not to allow oil adjustment screw ❶ to come off. 3. Never drain the oil in the oil tank even when RP hook (hook for dry head) is used.

– 19 – 3-11-2. How to confirm the amount of oil (oil splashes)

Amount of oil (oil splashes) confirmation paper Position to confirm the amountof oil (oil splashes)

Hook driving shaft front bushing Hook 25 mm Approx.

Approx. 70 mm 3 to 10 mm

* Use any paper available regardless of Bed the material.

Oil splashes confirmation paper Closely fit the paper against the wall surface of the bed. * Place the amount of oil (oil splashes) confirmation paper under the hook and keep it from the hook by 3 to 10 mm to confirm the amount.

* When carrying out the procedure described below in 2), confirm the state that the needle thread from the thread take-up lever to the needle and the bobbin thread are removed, the presser foot is lifted and the slide plate is removed. At this time, take extreme caution not to allow your fingers to come in contact with the hook. 1) If the machine has not been sufficiently warmed up for operation, make the machine run idle for approxi- mately three minutes. (Moderate intermittent operation) 2) Place the amount of oil (oil splashes) confirmation paper under the hook while the sewing machine is in operation. 3) Confirm that oil exists in the oil tank. 4) Confirmation of the amount of oil should be completed in five seconds. (Check the period of time with a watch.)

3-11-3. Sample showing the appropriate amount of oil

Appropriate amount of oil (small) Appropriate amount of oil (large)

Splashes of oil from the hook Splashes of oil from the hook

• DDL-8000A-PMS : 0.5 to 1 mm • DDL-8000A-PMS : 1 to 1.5 mm • DDL-8000A-PSH : 1 to 3 mm • DDL-8000A-PSH : 2 to 4 mm

1) The state given in the figure above shows the appropriate amount of oil (oil splashes). It is necessary to finely adjust the amount of oil in accordance with the sewing processes. However, do not excessively increase/decrease the amount of oil in the hook. (If the amount of oil is too small, the hook will be seized (the hook will be hot). If the amount of oil is too much, the sewing product may be stained with oil.) 2) Check the oil amount (oil splashes) three times (on the three sheets of paper), and adjust so that it should not change.

– 20 – 3-12. Adjusting the thread take-up spring and the thread take-up stroke

❺ ❹ [DDL-8000A-PMS] [DDL-8000A-PSH] C D ❽ ❾ ❾ ❽

❻ ❻ ❶ ❶ ❶ E A A F ❸ ❸

B B G H ❷ ❷

(1) Adjusting the stroke of thread take-up spring ❶ 1) Loosen setscrew ❷ . 2) Turn tension post ❸ clockwise (in direction A), the stroke of the thread take-up spring will be increased, and turn the post ❸ counterclockwise (in direction B), the stroke will be decreased. (2) Adjusting the pressure of thread take-up spring ❶ 1) Loosen setscrew ❷ , and remove thread tension (asm.) ❺ . 2) Loosen tension post setscrew ❹ . 3) Turn tension post ❸ clockwise (in direction A), the pressure will be increased, and turn the post ❸ counterclockwise (in direction B), the pressure will be decreased.

To check how the thread take-up spring works, draw out the needle thread in direction F after having adjusted the thread take-up spring pressure to check whether the thread take-up spring exerts force to the thread up to the last moment (state G) just before the thread comes out from E. If the spring fails to exert force to the spring until the last moment (state H), decrease the thread take-up spring pressure. In addition, the stroke of the thread take-up spring is excessively small, the spring does not work properly. For the general fabrics, a stroke of 10 to 13 mm is proper.

(3) Adjusting the thread take-up stroke 1) When sewing heavy-weight materials, move thread guide ❽ to the left (in direction C) to increase the length of thread pulled out by the thread take-up. 2) When sewing light-weight materials, move thread guide ❽ to the right (in direction D) to decrease the length of thread pulled out by the thread take-up.

* Standard state of the thread guide The standard distance between the right end face of thread guide and the screw head is as follows:

[DDL-8000A-PMS] [DDL-8000A-PSH]

4mm

< Destination AA and BB > 7mm

7mm

< Destination GG >

– 21 – 4. FOR THE OPERATOR

4-1. How to set the machine head and to initialize data (the factory-set state at the time of shipment)

* This item has been factory-adjusted at the time of shipment. Carry out the machine head setting procedure in the case the control box is replaced, or in any case where it is necessary. ❻ ❼

1) Refer to "4-6. Function setting" p. 31 and call the function setting No. P70 (A). A B ❽

2) Press ❼ to flash the set value (B) on and off. In this state, select the corresponding type of

machine head by pressing ❻ .

Set value = 2: DDL8000APMS Set value = 3: DDL8000APSH

3) Data is initialized by pressing ❽ . Then, the sewing machine returns to the normal sewing state.

* If you want to initialize the data, change the setting of the type of machine head to a different type, then select the desired type of machine head. Example) In the case the selected type of machine head is "2":

P70 Change the selected type of machine head from "2" to "3". Press ❽ .

Change the selected type of machine head again from "3" to "2". Press ❽ .

– 22 – 4-2. Operation panel

❼ -A ❻ -A ❼ -B

❻ -B ❽

❶ ❷ ❸ ❹ ❺ ❾

How long the key No. Function must be pressed Short time Used to changing over the automatic reverse feed stitching at the beginning of sewing to: Reverse feed stitching / Double reverse feed stitching / ❶ Disable Long time Used to change over the thread clamp operation between enable / disable Short time Used to change over the automatic reverse feed stitching at the end of sewing to: Reverse feed stitching / Double reverse feed stitching / Disable ❷ Long time Used to change over the needle bar stop position at the time of stopping the sewing machine between up and down Short time Used to set the type of stitching to free stitching

❸ Long time Used to change over the thread trimming operation between enable / disable. Short time Used to set the type of stitching to overlapped stitching

❹ Long time Used to change over the lifting of the presser foot during sewing between "automatically lift / not lift". Short time Used to carry out setting of the polygonal-shape stitching.

❺ Long time Used to changeover the automatic lifting of presser foot after thread trimming between lift / not lift Short time Used to increase the maximum sewing speed A ❻ Short time Used to decrease the maximum sewing speed B

– 23 – How long the key No. Function must be pressed Short time Used to set the number of reverse feed stitches (ABCD) at the beginning and end of sewing A Long time Used to change over the one-shot operation between enable / disable ❼ Short time Used to set the number of reverse feed stitches (ABCD) at the beginning B and end of sewing Long time Used to set the bobbin counter

Short time Used to determine the set data ❽

Short time Used to display the parameters registered to function key F1 ❾ Long time Used to register a parameter to function key F1 Short time Used to display the parameters registered to function key F2 Long time Used to register a parameter to function key F2 Short time Used to return the data being edited to the initial state

Short time Used to set the sewing machine clock right Long time Used to set the memory switch Short time Used to change over the display to the thread trimming counter display

- Speaker for the audio guidance

– 24 – 4-3. Audio guidance

The audio guidance provides the following information when turning ON / OFF the power to the sewing machine, operating the sewing machine and operating the operation panel. The guidance sound is emitted from

① At the time of turning the power ON �� "Hello. (month) (day), (date)" etc. ② At the time of turning the power OFF �� "Thank you for your hard work." etc. ③ At the time of operating the sewing machine �� "Oil level is low. Please refuel." �� "Oil tank is full." �� "Bobbin thread will be running out." �� Guidance on the production support "The current productivity achievement rate is at 105%" etc. �� "Kindly refer to the "Lists of errors" by using the QR code.", etc. ④ At the time of operating the operation panel �� The audio guide provides the modified parameter con- tent.

– 25 – 4-4. Setting the clock

The time displayed on the operation panel can be changed.

1) Press in the normal sewing state to display the time change screen.

❻ ❼

❽

2) The time setting items flash on and off in the order of "year", "month", "day ", "hour", "minute" and "sec-

ond". Select the item you want to change with ❼ . Then, change the value of that item with

❻ .

3) Press ❽ to determine the set value. Then, the sewing machine returns to the normal sewing state.

– 26 – 4-5. Operating procedure of the sewing pattern

4-5-1. Reverse feed stitching pattern Reverse feed stitching at sewing start and reverse feed stitching at sewing end can be separately programmed.

Display Display [Setting procedure of the reverse feed ❼ ❻ section A section B stitching] 1) The reverse feed stitching pattern at the beginning of sewing can be changed over to "enable / double reverse feed

stitching / disable" by pressing ❶.

The reverse feed stitching pattern at the end of sewing can be changed over to "enable / double reverse feed stitch-

ing / disable" by pressing ❷ . The ❶ ❷ current setting state of the reverse feed stitching is displayed on the display section A.

2) Press ❼ to put the sewing machine in the state where the number of reverse feed stitches can

be set. At this time, one of the items shown in the display section B flashes on and off. Move the item that flashes on and off to the target process (A, B, C or D) you want to set. Then, change

the set value for that process with ❻ .

The number which exceeds 9 is indicated as follows: A = 10, b = 11, c = 12, d = 13, E = 14, and F = 15.

– 27 – 4-5-2. Overlapped stitching pattern Overlapped stitching pattern can be programmed. A : Number of stitches of normal stitching setting : 0 to 15 stitches A C C B : Number of stitches of reverse stitching setting : 0 to 15 stitches C : Number of stitches of normal stitching setting : 0 to 15 stitches D : Number of times of repetition : 0 to 15 times

1. When process D is set to 5 times, the sewing is repeated as A B B → B → C → B → C. 2. The number which exceeds 9 is indicated as follows: D A = 10, b = 11, c = 12, d = 13, E = 14, and F = 15.

[Setting procedure of the overlapped stitching]

Display section B ❼ ❻

1) Press ❹ to enable the overlapped

stitching pattern. When the overlapped stitching pattern is enabled, is displayed in the display section C.

2) Press ❼ to put the sewing machine to the overlapped stitching ❹ Display setting state. In this state, one of the section C items displayed in the display section B flashes on and off. 3) Move the process that flashes on and off to the process (A, B, C or D) you want to set. Then, change the number of stitches and the number of times with

❻ .

– 28 – 4-5-3. Polygonal-shape stitching pattern A polygonal-shape stitching pattern can be set. As many as nine different patterns can be set. In addition, nine steps of stitching can be set in one pattern.

[How to set a polygonal-shape stitching pattern]

1) Press ❺ to put the sewing machine to the constant-dimension stitching pattern setting state. In this

state, one of the processes A, B and C flashes on and off.

2) Move the process that flashes on and off to the process (A, B or C) you want to set with ❼ .

Then, change the set value for that process with ❻ .

A : Selection of the pattern number B : Select what number of the step C : Set number of stitches of B ❻ ❼

A B C ❽

❺

* Constant-dimension stitching (Straight stitching) (Example) Select the pattern number to A. Set B to "1". Set the number stitches (1 - 999) of the first step toC . Set B to 2. Set C to 0 (zero). * Setting C to "0" means the end of constant-dimension stitching. In this case, the number of seams to be sewn using the constant-dimension stitching becomes "1".

After the completion of setting, press ❽ to determine the data.

* Polygonal-shape stitching (label sewing) (Example) Select the pattern number to A. Set B to "1". Set the number of stitches (1 - 999) in the first step toC . Similarly, set B to 2, to 3 and to 4 in sequence to set the number of stitches (1 to 999) of the second, third and fourth seam line. Set B to 5. Set C to 0 (zero). * Setting C to 0 (zero) means the end of polygonal-shape stitching. In this case, the number of seams to be sewn using the polygonal-shape stitching becomes "4". * In the initial setting, a polygonal-shape stitching pattern consisting of four steps (each steps consist of 12 stitches) has been factory set.

– 29 – Display

section D After the completion of setting, press ❽ to determine the data.

When the polygonal-shape stitching is

enabled, is displayed in the display

❽ section C. The selected pattern number is displayed in the display section D.

Display section C

– 30 – 4-6. Function setting The set value of the function setting can be changed.

❻ ❼ 1) The function setting screen is displayed

by keeping held pressed for

three seconds in the normal sewing state. A B ❽ A indicates the function setting number. B indicates the set value for that function setting number.

2) Press ❼ to flash function setting No. A on and off. In this state, press ❻ to select the function setting number you want to set. (The figure shows the function setting No. P08, that is used for setting the number stitches to be sewn using the soft-start function.)

3) Press ❼ to flash setting No.B on and off. In this state, change the set value by pressing

❻ .

4) Press ❽ to determine the set value.

5) Press to return the sewing machine to the normal sewing state.

In the case of changing the set value for other function setting number, repeat the steps of procedure 2), 3) and 4). Then, finally carry out step of procedure 5).

6) The function setting items are classified into two different levels; user level and service level. In the case of displaying the function setting items that are classified to the service level, turn the power

ON while keeping held pressed.

– 31 – 4-7. Setting the function keys (F1 and F2) The functions you use frequently can be registered to these two function keys. The set value of the function setting number that is registered can be directly changed by pressing ❾

and .

❻ 1) The function setting screen is displayed by keeping ❾ switch or

switch held pressed for three seconds A B in the normal sewing state. ❽ A indicates the function setting number. B indicates the set value for that function setting number. ❾

2) The display section A shows the function switch F1 or F2 you have pressed. The display section B shows the currently-registered function setting number that is flashing on and off.

3) Select the function setting number you want to register by pressing ❻ .

4) Press ❽ to determine the function setting number to be registered. Then, the sewing machine re-

turns to the normal setting state.

* If you want to registered the function setting that belongs to the service level, the power should be turned

ON, in prior, while keeping held pressed. Then, return to the sewing screen by pressing .

On the sewing screen, carry out the aforementioned steps of procedure 1) to 4).

– 32 – 4-8. Production support function The production support function provides two different functions to allow the operator to know the production status; one is "to know productivity based on the daily operation rate of the sewing machine" and the other is "to know the progress of sewing work based on the number of times of thread trimming".

4-8-1. How to set the production support parameters

1) Press in the normal sewing

state to display the production support screen.

< Production support screen >

❻ ❼

2) Display the production support param-

eters by keeping held pressed for three seconds on this screen. A B ❽

3) Press ❼ to flash the parameter No. A on and off. In this state, select the parameter number

you want to set by pressing ❻ .

4) Press ❼ to flash the set value B on and off. In this state, change the set value by press-

ing ❻ .

5) Press ❽ to determine the set value. Press to return the screen to the previous screen.

– 33 – 4-8-2. List of production support parameters Display Display section C section D

Display Display Display section A section B section E

< Function setting screen > < Production support screen >

No. Item Setting range Initial value Target number of The target number of pieces to be produced within the work U01 pieces to be pro- hours set with parameters U03 and U04 is set with this 1 to 1999 500 duced per day parameter. (Display section B) Number of times The number of times of thread trimming to be carried out of thread trimming until the counter counts one is set with this parameter. U02 1 to 99 1 for one count of (Display section B) product Work hours (from The starting time and the finishing time of sewing work is U03 the starting time to set with this parameter. 8:00 to to 0:00 to 23:59 the finishing time) * The operation rate is calculated using the work hours 17:00 U04 excluding the time of work breaks. U05 Work break 1 (from The starting time and the finishing time of a work break is 12:00 to to the starting time to set with this parameter. In the case no work break is provid- 13:00 U06 the finishing time) ed, this parameters should be "0000". U07 Work break 2 (from (Caution) 0:00 to to the starting time to * For U05 - U06, U07 - U08 and U09 - U10, enter the time 0:00 to 23:59 0:00 U08 the finishing time) in the order from the earliest to latest. * In the case the work break is not provided within the work U09 Work break 3 (from hours (U03 - U04), "non" will be displayed. Only the data 0:00 to to the starting time to for which "non" is not displayed are effective. 0:00 U10 the finishing time) Type of display of The type of display for the target number of pieces to be the target number produced (display section D) is changed over with this pa- of pieces to be rameter. produced 1: The target number of pieces at the current time is displayed by calculating it at all times. * Display section E: The actual number of pieces pro- U11 duced at the current time / The target number of pieces 0 - 1 0 to be produced at the current time × 100 (%) 0: The target number of pieces to be produced for the day is displayed. * Display section E: The actual number of pieces produced for the day / The target number of pieces to be produced for the day × 100 (%) Changeover of the The display of the operation rate (display section E) is display of operation changed over between ON / OFF. U12 0 - 1 1 rate between ON / 1: Operation rate is displayed OFF 0: Operation rate is not displayed * In the case the daily production quantity exceeds 1999, set the production support parameter:U02 to "10". Then, the "number of pieces counter" adds one every time the sewing machine has carried out thread trimming by 10 times.

– 34 – 4-8-3. How to display the operation rate of the sewing machine

1) Setting the production support parameters

No. Item Setting range Initial value Changeover of the The display of the operation rate (display section E) is display of operation changed over between ON / OFF. U12 0 - 1 1 rate between ON / 1: Operation rate is displayed OFF 0: Operation rate is not displayed

When this parameter is set to "1", the operation rate of the sewing machine is displayed in the normal sewing state and on the production support screen. (Display section E)

Display section E < Sewing-machine operation state display state >

Display section E

< Target achievement rate display screen >

Operation rate calculating method: Time during which the sewing machine runs from the starting time (U03) of work hours to the current time Operation rate (excluding the work break) of the sewing = machine Work hours from the work starting time (U03) to the current time × 100 (excluding the work break)

2) When you keep held pressed for three seconds, the display on the display section E is

changed over between the "operation rate of sewing machine" and the "target achievement rate".

Display section E: Display section E: Display of the sewing-machine operation rate Display of the target achievement rate ⇔

– 35 – 4-8-4. How to display the number of pieces produced

Display Display section C section D ❼ ❻ 1) Press in the normal sewing

state. Then, the “number of pieces produced” display screen displayed.

Display section E

< Number of pieces produced display screen >

2) The number of pieces produced for the data is displayed on the display section C. Every time the sewing machine performs sewing and thread trimming, "1" is added to the current value displayed in the display section C. The number of pieces produced for the day displayed in the display section C can be increased / de-

creased by pressing ❻ .

* The number of pieces produced and the target number of pieces are reset to 0 (zero) two hours before the starting time of work hours (U03). 3) The item displayed in the display section D can be changed over by setting the production support parameter.

No. Item Setting range Initial value Type of display of The type of display for the target number of pieces to be the target number produced (display section D) is changed over with this pa- of pieces to be rameter. produced 1: The target number of pieces at the current time is displayed by calculating it at all times. * Display section E: The actual number of pieces pro- U11 duced at the current time / The target number of pieces 0 - 1 0 to be produced at the current time × 100 (%) 0: The target number of pieces to be produced for the day is displayed. * Display section E: The actual number of pieces produced for the day / The target number of pieces to be produced for the day × 100 (%) * Changeover of the aforementioned type of display will also change the method to calculate the percentage of the number of pieces produced that is displayed in the display section E.

– 36 – 4-9. Function setting list

No. Item Description Level Setting range Default P01 Maximum sewing speed The maximum sewing speed reached by fully depressing the U 100-[P68] MS：4000 pedal is set with this function setting item. The maximum sewing (sti/min) SH：3500 speed can be changed within the sewing speed range specified for [P68 Maximum sewing speed]. * The maximum sewing speed can also be changed using the + - switch on the operation panel. P02 Tilt of the pedal Change in the sewing speed with respect to the depressing depth S 10-100(%) 80 of the pedal is set with this function setting item. The sewing speed is increased abruptly when this parameter is set to a large value, or increased slowly when this parameter is set to a small value. P04 Reverse feed stitching The sewing speed to be used during the reverse feed stitching at U 100-3000 1900 speed at the beginning of the beginning of sewing is set with this function setting item. (sti/min) sewing P05 Reverse feed stitching The sewing speed to be used during the reverse feed stitching at U 100-3000 1900 speed at the end of sewing the end of sewing is set with this function setting item. (sti/min) P06 Overlapped stitching speed The sewing speed to be used during the overlapped stitching is U 100-3000 1900 set with this function setting item. (sti/min) * This speed can also be changed using the relevant switch on the operation panel. P07 Sewing speed for soft start The sewing speed for soft start at the beginning of sewing is set U 100-1500 800 with this function setting item. (sti/min) P08 Soft start function The number of stitches to be sewn with the soft-start function at U 0-99 1 the beginning of sewing is set with this function setting item. (Stitches) 0: The soft-start function is not selected 1 - 9: The number of stitches to be sewn with the soft-start function P09 Sewing speed for the polyg- Sewing speed for the polygona-shape stitching is set with this U 200-[P68] MS：4000 onal-shape stitching function setting item. (sti/min) SH：3500 * The sewing speed can also be changed using the + - switch on the operation panel. P10 Setting of the reverse feed Whether the reverse feed stitching is automatically carried out U ON/OFF ON stitching at the end of end of at the end of polygonal-shape stitching is set with this function polygonal-shape stitching setting item. ON: Reverse feed stitching is automatically performed at the end of sewing OFF: Sewing machine stops sewing before starting reverse feed stitching at the end of sewing. It performs reverse feed stitching when the front part of pedal is depressed. P12 Changeover of the reverse The sewing speed for the reverse feed stitching at the beginning U 0-1 1 feed stitching at the start of sewing is set with this function setting item. of sewing between Auto / 0: The reverse feed stitching is performed by manually operating Manual the pedal. 1: The reverse feed stitching is performed at the sewing speed set with [P04 Reverse feed stitching speed at the beginning of sewing]. P13 Function of stop immedi- Operation to be carried out at the end of the reverse feed stitching U CON/STP CON ately after the reverse feed at the beginning of sewing is selected with this function setting stitching at the beginning of item. sewing CON: The sewing machine does not stop temporarily after completion of the reverse feed stitching at the beginning of sewing STP: The sewing machine stops temporarily after completion of the reverse feed stitching at the beginning of sewing P15 Changeover of the needle The function of needle up/down correction switch is changed over U 0-3 0 up/down correction function with this function setting item. 0: Needle up/down correction 1: One stitch correction 2: Continuous half stitch 3: Continuous one stitch P16 Speed limit to reverse-feed The speed limit applied when reverse feed stitching is carried out S 0-4000 0 stitching is set with this function. (sti/min) 0: No speed limit 10 - 3000: Sewing is performed at the set sewing speed P18 Correction of solenoid-on Stitch alignment can be carried out by changing the timing of U 0-200 123 timing for the reverse feed actuating the reverse-feed stitching solenoid at the time of reverse stitching at the beginning of feed stitching at the beginning of sewing. When the set value for sewing this parameter is increased, the length of stitch at the end of A process is increased and the length of stitch at the beginning of B process is decreased. P19 Correction of solenoid-off Stitch alignment can be carried out by changing the timing of U 0-200 130 timing for the reverse feed releasing the reverse-feed stitching solenoid at the time of reverse stitching at the beginning of feed stitching at the beginning of sewing. When the set value for sewing this parameter is increased, the length of stitch at the beginning of B process is increased. ＊ P21 Low-speed section by pedal Start position of sewing by operating the pedal is set with this S 30-1000 520 function setting item. ＊ P22 Sewing starting position by Releasing position of pedal operation is set with this function S 30-1000 420 pedal setting item. ＊ P23 Position to lift the presser The position to lift the presser foot by operating the pedal is set S 30-1000 270 foot by pedal with this function setting item. ＊ Do not change the set values with asterisk (*) mark as they are functions for maintenance. If the standard set value set at the time of delivery is changed, it is in danger of causing the machine to be broken or the performance to be deteriorated. If it is necessary to change the set value, please purchase the Engineer’s Manual and follow the instructions.

– 37 – No. Item Description Level Setting range Default ＊ P24 Position to perform thread The position to perform thread trimming by operating the pedal is S 30-500 130 trimming by pedal set with this function setting item. P25 Correction of solenoid-on Stitch alignment can be carried out by changing the timing of U 0-200 123 timing for the reverse feed actuating the reverse-feed stitching solenoid at the time of reverse stitching at the end of sew- feed stitching at the end of sewing. When the set value for this ing parameter is increased, the length of stitch at the beginning of C process is increased. P26 Correction of solenoid-off Stitch alignment can be carried out by changing the timing of U 0-200 130 timing for the reverse feed releasing the reverse-feed stitching solenoid at the time of reverse stitching at the end of sew- feed stitching at the end of sewing. When the set value for this pa- ing rameter is increased, the length of stitch at the end of C process is decreased and the length of stitch at the beginning of D process is increased. ＊ P29 Brake force of the main Main shaft brake force is adjusted with this function setting item S 1-45 30 shaft at the time of stopping for preventing the sewing machine from overrunning before stop- the sewing machine after ping. thread trimming P32 Correction of solenoid-on Stitch alignment can be carried out by changing the timing of actu- U 0-200 MS：105 timing for the overlapped ating the reverse feed stitching solenoid at the time of overlapped SH：92 stitching stitching. When the set value for this parameter is increased, the length of stitch at the end of A (C) process is increased and the length of stitch at the beginning of B process is decreased. P33 Correction of solenoid-off Stitch alignment can be carried out by changing the timing U 0-200 MS：105 timing for the overlapped of releasing the reverse-feed stitching solenoid at the time of SH：100 stitching overlapped stitching. When the set value for this parameter is increased, the length of stitch at the end of B process is increased and the length of stitch at the beginning of C process is decreased. P37 First current value (ON duty) The first current value (ON duty) for the thread clamp is set with U 0-100 MS：40 of thread clamp this function setting item. SH：50 * Refer to the "explanation of the thread clamp solenoid operation" in the Engineer's Manual for details. ＊ P44 Brake force of the main Main shaft brake force is adjusted with this function setting item S 1-45 16 shaft at the time of stopping for preventing the sewing machine from overrunning before stop- the sewing machine on the ping on the way. way P45 ON duty of the reverse feed Output duty of the reverse feed stitching solenoid when the sole- S 1-50 30 stitching solenoid noid is in the ON state is set with this function setting item. P46 Setting of the function of This function rotates the main shaft in the reverse direction of U ON/OFF OFF reverse revolution to lift the sewing to bring the needle bar to the highest position. needle ON: Reverse-revolution operation is in the ON state OFF: Reverse-revolution operation is in the OFF state P47 Reverse revolution angle to The operating angle of the reverse-revolution to lift the needle is S 50-200 160 lift the needle adjusted with this function setting item. (1/4°) P48 Sewing speed at a low The minimum sewing speed of the sewing machine by operating U 100-500 200 speed the pedal is set with this function setting item. (sti/min) P49 Sewing speed for thread Sewing speed to be used when performing thread trimming is set U 100-500 210 trimming with this function setting item. (sti/min) ＊ P50 2nd thread trimming speed Sewing speed is decreased in the latter half of thread trimming S 0-500 180 operation. That sewing speed is set with this function setting item. (sti/min) * In the case this speed is set to "0" (zero), the sewing machine runs at the 1st thread trimming speed. ＊ P51 Timing to change over to the The timing to change over the sewing speed to the 2nd thread S 270-370(°) 320 2nd thread trimming speed trimming speed is set with this function setting item. ＊ P52 Time to wait for sewing after The time to wait for starting sewing after the presser foot is low- S 10-500(ms) 120 lowering the presser foot ered is set with this function setting item. P53 Setting of operation of the The operation of the presser foot when the back part of pedal is U 0-2 1 presser foot when the back depressed is set with this function setting item. part of pedal is depressed 0: Presser foot does not operate even when the back part of pedal is depressed. 1: Presser foot goes up to the 1st presser-foot lifting position when the back part of pedal is depressed by half of the depth. It goes up to the 2nd presser-foot lifting position when the back part of the pedal is further depressed. 2: Presser foot does not operate even when the back part of pedal is depressed. It goes up to the 2nd presser-foot lifting position when the back part of the pedal is further depressed. P68 Maximum sewing speed The maximum sewing speed is set with this function setting item. S 100-MAX MS：4000 (The MAX value differs with the type of machine head. (sti/min) SH：3500 MS: 5000; SH: 4500) P70 Machine head selection Machine head type is selected with this function setting item. S 2-3 2 (Initialization of data) 2: DDL-8000APMS 3: DDL-8000APSH * When you select the corresponding machine head and press the enter switch, all existing data are initialized to the initial values for the machine head you have selected. P72 Adjustment mode for the The current main shaft angle is always displayed in the data S 0-1439 needle-up stop angle display section. When you turn the pulley to bring the main shaft (1/4°) to the needle-up stop position and press the enter switch, the needle-up angle and needle-down angle of the main shaft are automatically set. ＊ Do not change the set values with asterisk (*) mark as they are functions for maintenance. If the standard set value set at the time of delivery is changed, it is in danger of causing the machine to be broken or the performance to be deteriorated. If it is necessary to change the set value, please purchase the Engineer’s Manual and follow the instructions.

– 38 – No. Item Description Level Setting range Default P73 Adjustment mode for the The current main shaft angle is always displayed in the data S 0-1439 needle-down stop angle display section. When you turn the pulley to bring the main shaft (1/4°) to the needle-down stop position and press the enter switch, the only the needle-down angle of the main shaft is automatically set. ＊ P74 Back-tack solenoid OFF Back-tack solenoid OFF parameter S 0-990 3 parameter * Refer to the explanation of operation of the BT solenoid in the Engineer's Manual for details. ＊ P75 Back-tack solenoid OFF Back-tack solenoid OFF parameter S 0-990 10 parameter * Refer to the explanation of operation of the BT solenoid in the Engineer's Manual for details. ＊ P76 Back-tack solenoid ON Back-tack solenoid ON parameter S 10-990 200 parameter * Refer to the explanation of operation of the BT solenoid in the Engineer's Manual for details. P77 Back-tack solenoid ON The BT solenoid ON timing at the end of sewing is set with this U 50-500 150 timing at the end of sewing function setting item. * This parameter applies only to the free stitching. P78 Thread clamp ON angle ON-angle of the thread clamp is set with this function setting item. U 0-359 220 (°) P79 Thread clamp OFF angle OFF-angle of the thread clamp is set with this function setting U 0-359 300 item. (°) P87 Wiper operating time The time during which the wiper is turned ON is set with this func- S 10-990(ms) 50 tion setting item. P93 Reaction time when the The reaction time required to start lifting of the presser foot after S 10-990(ms) 100 back part of pedal is de- the back part of the pedal is depressed is set with this function pressed setting item. P109 Wiper operation timing The waiting time required until the wiper starts operation after the S 5-990 5 sewing machine stops with its needle up. P110 Waiting time until the sewing The waiting time required until the sewing machine starts next S 0-250 100 machine starts next sewing sewing after the thread trimming solenoid is turned OFF. P112 Needle-up stop angle The angle from the upper dead point of needle to the needle-up S −359 - 359 (°) −55 stop position is set with this function setting item. P113 Bobbin counter The largest value that the bobbin counter can count is set with U 0-9999 500 this function setting item. When the counter reaches that value, it (10 stitches) stops counting. ＊ P114 Reverse feed solenoid oper- The angle at which the solenoid output is prohibited (start) after S 0-359 (°) 262 ation stopping angle (start) pressing the reverse-feed stitching on the way switch. ＊ P115 Reverse feed solenoid oper- The angle at which the solenoid output is prohibited (end) after S 0-359 (°) 112 ation stopping angle (end) pressing the reverse-feed stitching on the way switch. P116 Function of prohibiting the The correction stitching function when turning the pulley by hand U 0-1 0 correction operation after upon completion of the polygonal-shape stitching is set with this turning the handwheel by function setting item. hand 0: Correction sewing function is enabled 1: Correction sewing function is disabled P117 Thread trimming operation The thread trimming operation after turning the pulley by hand to U 0-1 1 after turning the handwheel move the sewing machine from the upper and lower positions is by hand set with this function setting item. 0: Thread trimming operation is carried out after turning the pulley by hand 1: Thread trimming operation is not carried out after turning the pulley by hand. P118 Setting of the needle up/ The operation of the needle up/down switch after thread trimming U 0-1 0 down switch operation after is set with this function setting item. thread trimming 0: Needle up/down operation is carried out 1: One-stitch operation is carried out P128 Number of condensation The number of condensation stitches at the beginning of sewing U 0-5(stitches) 0 stitches at the beginning of is set with this function setting item. sewing P129 Number of condensation The number of condensation stitches at the end of sewing is set U 0-5(stitches) 0 stitches at the end of sewing with this function setting item. P130 Condensation stitching The sewing speed for condensation stitching at the end of sewing U 100-1900 310 speed at the end of sewing is set with this function setting item. (sti/min) P131 Condensation stitching The sewing speed for condensation stitching at the beginning of U 0-1900 310 speed at the beginning of sewing is set with this function setting item. (sti/min) sewing ＊ P132 Condensation solenoid ON duty of the condensation solenoid when it starts operation is S 1-80(%) 55 operation starting duty set with this function setting item. ＊ P133 Condensation solenoid duty The duty of the condensation solenoid while it is in operation is S 1-80(%) 10 while it is in operation set with this function setting item. ＊ P134 Condensation solenoid The operation starting time for the condensation solenoid is set S 10-150(ms) 115 operation starting time with this function setting item. ＊ P135 Condensation solenoid The operation starting angle for the condensation solenoid is set S 10-359(°) 75 operation starting angle with this function setting item. P136 Selection of the presser foot Operation of the presser foot when the power is turned ON is U 0-2 0 operation when the power is selected with this function setting item. turned ON 0: The presser foot does not operate (It operates when the back part of the pedal is depressed.) 1: The presser foot goes up after automatically retrieving the origin 2: The presser foot comes down after automatically retrieving the origin ＊ Do not change the set values with asterisk (*) mark as they are functions for maintenance. If the standard set value set at the time of delivery is changed, it is in danger of causing the machine to be broken or the performance to be deteriorated. If it is necessary to change the set value, please purchase the Engineer’s Manual and follow the instructions. – 39 – No. Item Description Level Setting range Default P138 Function of pedal curve Pedal curve is selected. (Improving pedal inching operation) U 0-2 0 selection 2

Sewing speed 0 1

Pedal stroke

P139 Function of reverse feed The function activated when the reverse feed stitching on the way U 0-1 0 stitching on the way switch is pressed is selected with this function setting item. 0: Normal back-tack function 1: Function of reverse feed stitching on the way is enabled P140 Number of stitches of The number of stitches of reverse feed stitching on the way is set U 1-19 4 reverse feed stitching on the with this function setting item. way P141 Condition to be satisfied The condition to be satisfied to enable the reverse feed stitching U 0-1 0 to enable the reverse feed switch while the sewing machine is at rest is set with this function stitching on the way while setting item. the sewing machine is at 0: Disabled while the sewing machine is at rest rest 1: Enabled while the sewing machine is at rest P142 Thread trimming function Automatic thread trimming operation after performing the reverse U 0-1 0 after performing reverse feed stitching on the way is set with this function setting item. feed stitching on the way 0: Automatic thread trimming is not performed after the completion of reverse feed stitching on the way 1: Automatic thread trimming is performed after the completion of reverse feed stitching on the way P143 Sewing speed for reverse Sewing speed during the reverse feed stitching on the way is set U 200-3000 1900 feed stitching on the way with this function setting item. (sti/min) P145 ON/OFF of the data output Output of data to JANET is set with this function setting item. S 0-1 0 to JANET 0: Data is not output to JANET 1: Data is output to JANET P146 Waiting time to start opera- Waiting time until the start of operation of the (bird's nest prevent- U 0-990 150 tion of thread pulling cylinder ing) thread pulling cylinder is set with this function setting item. P147 Thread pulling cylinder ON The time to turn ON the (bird's nest preventing) thread pulling U 0-990 120 time cylinder is set with this function setting item. P148 Time until sewing starts The waiting time required until the sewing machine starts next S 0-990 30 after turning OFF the thread sewing after turning OFF the (bird's nest preventing) thread pull- pulling cylinder ing cylinder is set with this function setting item. ＊ P149 Back-tack solenoid ON Back-tack solenoid ON parameter S 50-100 50 parameter * Refer to the explanation of operation of the BT solenoid in the Engineer's Manual for details. ＊ P150 Back-tack solenoid OFF Back-tack solenoid OFF parameter S 2-500 2 parameter * Refer to the explanation of operation of the BT solenoid in the Engineer's Manual for details. P151 ON/OFF of the bird's nest (Bird's nest preventing) ON/OFF of the bird's nest preventing U 0-1 0 preventing operation operation is set with this function setting item. P152 Waiting time until the wiper (Bird's nest preventing)The waiting time required until the wiper S 0-990(ms) 10 cylinder starts operation cylinder starts operation is set with this function setting item. P153 Wiper cylinder ON time (Bird's nest preventing) ON time of the wiper cylinder is set with U 0-990(ms) 150 this function setting item. P154 Time until sewing starts (Bird's nest preventing) The waiting time required until the sewing S 0-990(ms) 30 after turning OFF the wiper machine starts the next sewing after turning OFF the wiper cylin- cylinder der is set with this function setting item. P155 Wiper output duty (Bird's nest preventing) ON duty of the wiper output is set with this S 0-100(%) 90 function setting item. P159 Suction ON/OFF (Bird's nest preventing) ON/OFF of the suction device is set with S 0-1 1 this function setting item. P160 Suction time (Bird's nest preventing) Suction time is set with this function set- S 5-5000(ms) 500 ting item. P161 The presser foot lifting The presser foot lifting operation ON/OFF when the thread clamp S 0-1 0 operation ON/OFF when the works is set with this function setting item. thread clamp works 0: OFF 1: ON P162 The angle at which the The angle at which the presser foot starts going up when the S 0-359 100 presser foot starts going thread clamp work is set with this function setting item. up when the thread clamp works. P163 Ending angle of soft start for The ending angle of the soft start for the thread clamp is set with U 0-359 340 the thread clamp this function setting item. * Refer to the explanation of operation of the thread clamp solenoid in the Engineer's Manual for details. P164 Setting of the lifting amount The lifting amount of the presser foot when the thread clamp S 0-500 50 of the presser foot when the works is set with this function setting item. thread clamp works P165 Time during which the The time during which the presser foot goes up when clamping S 1-990 20 presser foot goes up when the thread is set with this function setting item. clamping the thread P166 1st electric current time for Period of time during which the 1st electric current is fed applied U 1-990 7 thread clamp to the thread clamp is set with this function setting item. * Refer to the explanation of operation of the thread clamp solenoid in the Engineer's Manual for details. ＊ Do not change the set values with asterisk (*) mark as they are functions for maintenance. If the standard set value set at the time of delivery is changed, it is in danger of causing the machine to be broken or the performance to be deteriorated. If it is necessary to change the set value, please purchase the Engineer’s Manual and follow the instructions. – 40 – No. Item Description Level Setting range Default P167 2nd electric current value for “ON duty” is set in order to determine the 2nd electric current U 0-100 69 thread clamp (ON duty) value of the thread clamp * Refer to the explanation of operation of the thread clamp solenoid in the Engineer's Manual for details. ＊ P168 Back-tack solenoid ON Back-tack solenoid ON parameter S 1-200 25 parameter * Refer to the explanation of operation of the back-tack solenoid in the Engineer's Manual for details. ＊ P169 Back-tack solenoid ON Back-tack solenoid ON parameter S 1-200 40 parameter * Refer to the explanation of operation of the back-tack solenoid in the Engineer's Manual for details. ＊ P170 Back-tack solenoid OFF Back-tack solenoid OFF parameter S 1-200 10 parameter * Refer to the explanation of operation of the back-tack solenoid in the Engineer's Manual for details. ＊ Do not change the set values with asterisk (*) mark as they are functions for maintenance. If the standard set value set at the time of delivery is changed, it is in danger of causing the machine to be broken or the performance to be deteriorated. If it is necessary to change the set value, please purchase the Engineer’s Manual and follow the instructions.

No. Item Description Level Setting range Default J04 Selection of language for the The language for the audio function is selected with U 1-2 2 audio function this function setting item. 1: Chinese 2: English J05 Audio ON/OFF function ON/OFF of the audio guidance is set with this function U 0-2 2 setting item. 0: All audio guidance is set to OFF 1: Only the panel operation guidance is enabled 2: All audio guidance is set to ON. * When this item is set to "1", the audio guidance for " ③ At the time of operating the sewing machine; Guidance on the production support" ("4-3. Audio guidance" p. 25) is placed in OFF. J10 Setting of brightness of the back- Brightness of the backlight is set with this function U 1-3 3 light setting item. J11 Energy saving mode Time to turn OFF the backlight of LCD when the panel U 0-20(min) 0 is not operated is set with this function setting item. 0: The backlight is not turned OFF 1 - 20: Time to be elapsed before turning OFF the backlight J14 Password If the password is set to a number other than "0000", S 0000-9999 0 the password entry screen will be displayed before displaying the function setting screen by pressing the M switch.

③ At the time of operating the sewing machine Guidance on the production support

No. Item Description Level Setting range Default Main software version Main software version is displayed with this function U N01 setting item. Panel software version Panel software version is displayed with this function U N02 setting item. N14 ST motor software version Version of the stepping motor control software is dis- U played with this function setting item. N15 Number of stitches to stop the The number of stitches sewn is monitored in order to S grease counter notify the operator of the timing of replenishing grease. Unit: (× 100,000 stitches) When the grease counter value reaches 800,000,000 stitches, the grease shortage warning "E220" occurs. When the grease counter value reaches 900,000,000 stitches, the grease shortage error "E221" occurs. * The grease counter is cleared to "0" (zero).

– 41 – 4-10. Detailed explanation of selection of functions

① Selection of the soft-start function (Function setting No. P08) The needle thread may fail to interlace with the bobbin thread at the start of sewing when the stitching pitch (stitch length) is small or a thick needle is used. To solve such problem, this function (called “soft-start”) is used to limit the sewing speed, thereby assuring successful formation of the starting stitches. P 0 8 0 : The function is not selected. 1 to 9 : The number of stitches to be sewn under the soft-start mode. The sewing speed limited by the soft-start function can be changed. (Function setting No. P07) P 0 7 Data setting range : 100 to 1500 [sti/min] <10 sti/min>

② Changeover of the needle up/down switch function (Function setting No. P15) The function of the needle up/down switch is changed over with this function setting number. P 1 5 0 : Needle up/down correction 1: One-stitch correction 2: Continuous half stitch 3: Continuous one stitch

③ Function of reverse feed stitching on the way (Function setting Nos. P139 to P143) Functions of the limit of number of stitches and thread trimming command can be added to the touch back switch on the sewing machine head. Function setting No.139 Function of reverse feed stitching on the way is selected. 1 3 9 0 : OFF Normal back-tack function 1 : ON Function of reverse feed stitching on the way

Function setting No.140 Number of stitches performing reverse feed stitching is set. 1 4 0 Setting range : 0 to 19 stitches Function setting No.141 Effective condition of reverse feed stitching on the way 1 4 1 0 : OFF Inoperative when the sewing machine stops. (The reverse feed stitching on the way functions only while the sewing machine is in operation.) 1 : ON Operative when the sewing machine stops. (The reverse feed stitching on the way functions while both the sewing machine is in operation and is at rest.)

(Caution) Either condition is operative when the sewing machine is running.

Function setting No.142 Thread trimming is performed when reverse feed stitching on the way is completed. 1 4 2 0 : OFF Without thread trimming 1 : ON Thread trimming is executed.

Function setting No.143 Set the sewing speed when the reverse feed stitching at midpoint of sewing is performed. 1 4 3 Setting range : 200 to 3000 [sti/min] <10 sti/min>

– 42 – Function setting Application Output function No. P139 No. P141 No . P142 It works as normal touch-back switch. ❶ 0 0 or 1 0 or 1

When operating touch-back switch at the time of depressing front part ❷ 1 0 0 of the pedal, reverse feed stitching as many as the number of stitches specified by the function setting No. P140 can be performed. When operating touch-back switch at the time of either stop of the sewing machine or depressing front part of the pedal, reverse feed ❸ 1 1 0 stitching as many as the number of stitches specified by the function setting No. P140 can be performed. When operating touch-back switch at the time of depressing front part of the pedal, automatic thread trimming is performed after reverse ❹ 1 0 1 feed stitching as many as the number of stitches specified by the function setting No. P140 has been performed. When operating touch-back switch at the time of either stop of the sewing machine or depressing front part of the pedal, automatic ❺ 1 1 1 thread trimming is performed after reverse feed stitching as many as the number of stitches specified by the function setting No. P140 has been performed.

Actions under each setting state ❶ Used as the normal reverse feed stitching touch-back switch. ❷ Used for reinforcing seam (press sewing) of the pleats. (It works only while the sewing machine is in operation) ❸ Used for reinforcing seam (press sewing) of the pleats. (It works either when the sewing machine stops or when the sewing machine is running.) ❹ Used as starting switch for reverse feed stitching at the sewing end. (Used as the substitute for thread trimming by depressing back part of the pedal. It works only while the sewing machine is in operation. This is especially effective when the sewing machine used as the sewing machine for standing work.) ❺ Used as starting switch for reverse feed stitching at the sewing end. (Used as the substitute for thread trimming by depressing back part of the pedal. It works either when the sewing machine stops or when the sewing machine is running. It is especially effective when the sewing machine is used as the standing-work machine.)

– 43 – ④ How to balance stitches for [Start Back-Tacking] (Function setting Nos. P18 and P19) Example) Step 1: Setting stitch number for Start Back-Tacking A and B = 3 Step 2: Sewing the pattern in normal speed. Step 3: If unbalanced situation is appeared please correct it as below: Suggestion: Select the balance stitches for Section A before selecting for B.

Start point

A Case 1 : Longer A and shorter B B Adjustment : [P18] Decrease the set value. A becomes shorter and B becomes longer.

Start point A Case 2 : Shorter A and longer B B Adjustment : [P18] Increase the set value. A becomes longer and B becomes shorter.

Start point A Case 3 : Normal A and longer B Adjustment : [P19] Decrease the set value. B B becomes shorter.

Start point

A Case 4 : Normal A and shorter B Adjustment : [P19] Increase the set value. B B becomes longer.

– 44 – ⑤ How to balance stitches for [End Back-Tacking] (Function setting Nos. P25, P27 and P77) Example) Step 1: Setting stitch number for End Back-Tacking C and D = 3 Step 2: Sewing the pattern in normal speed. Step 3: If unbalanced situation is appeared please correct it as below: Suggestion: Select the balance stitches for Section C before selecting for D.

Case 1 : Longer C and shorter D C D Adjustment : [P26] Decrease the set value. C becomes shorter and D becomes longer.

Start point

Case 2 : Shorter C and normal D C Adjustment : [P26] Increase the set value. C becomes longer and D becomes shorter. D

Start point

Case 3 : C is longer. C Adjustment : [P77] Change the set value to such a value that D shortens C.

Start point

Case 4 : C is short. C Adjustment : [P77] Increase the set value. C becomes longer. D

Start point

C Case 5 : Normal C and longer D C Adjustment : [P25] Decrease the set value. D C becomes longer and D becomes shorter.

Start point

C Case 6 : Normal C and shorter D D Adjustment : [P25] Increase the set value. C becomes shorter and D becomes longer.

Start point

– 45 – ⑥ How to balance stitches for [Bar Tacking] (Function setting Nos. P32 and P33) Example) Step 1: Setting stitch number for Bar-Tacking A = B = 4 and turns of Bar-Tacking D = 4 Step 2: Sewing the pattern in normal speed. Step 3: If unbalanced situation is appeared please correct it as below:

Start point A B Case 1 : Longer A and shorter B Adjustment : [P32] Decrease the set value. A B A becomes shorter and B becomes longer.

B Start point Case 2 : Shorter A and normal B A A B Adjustment : [P32] Increase the set value. A becomes longer and B becomes shorter.

Start point A B Case 3 : Normal A and longer B Adjustment : [P33] Decrease the set value. B A B becomes shorter.

Start point A Case 4 : Normal A and shorter B B Adjustment : [P33] Increase the set value. B B becomes longer. A D

– 46 – ⑦ Function of pedal curve selection (Function setting No. P138) This function can perform the selection of the curve of sewing speed of the sewing machine against the depressing amount of the pedal. Change to this function when you feel that inching operation is hard or that pedal response is slow. 1 3 8 0 : Sewing speed in terms of the depressing amount of the pedal increases linearly. 1 : Reaction to intermediate speed in terms of the depressing amount of the pedal is de- layed. 2 : Reaction to intermediate speed in terms of the depressing amount of the pedal is ad- vanced. 2

0 1 Sewing speed (sti/min) Pedal stroke (mm)

⑧ Selection of the presser foot operation when the power is turned ON (Function setting No. P136) The needle bar goes up to its upper position and the presser motor carries out origin retrieval operation immediately after the power is turned ON. 1 3 6 0: Neither the needle bar nor the presser motor (Operates when the back part of pedal is depressed) 1: Needle bar goes up to its upper position and the presser motor automatically goes up after automatic origin retrieval. 2: Needle bar automatically goes up to its upper position and the presser motor comes down after automatic origin retrieval.

⑨ Setting of the operation of needle up/down switch after thread trimming (Function setting No. P118) One stitch operation can be performed only when the needle up / down compensating switch is pressed at the time of upper stop immediately after turning ON the power switch or upper stop immediately after thread trimming. 1 1 8 0 : Normal (Only needle up / down compensating stitching operation) 1 : One stitch compensating stitching operation (upper stop / upper stop) is performed only when aforementioned changeover is made.

⑩ Setting of max. sewing speed (Function setting No. P68) This function can set the max. sewing speed you desire to use. Upper limit of the set value varies in accordance with the sewing machine head to be connected. P 6 8 Setting range : 100 to MAX. sti/min <10 / sti/min> DDL8000A-PMS：5000 sti/min DDL8000A-PSH：4500 sti/min

– 47 – 4-11. How to use the bobbin counter In the case the number of stitches that can be counted on the bobbin counter (Function setting number P113) is set to "x10", the bobbin count complete screen is displayed when the bobbin counter reaches the set value to notify the operator that the bobbin has to be changed. ❻ ❼

1) Call function setting No. P113 referring to "4-6. Function setting" p. 31.

A B

❽

2) Press ❼ to flash the setvalue B on and off. Then, set the bobbin counter value by pressing

❻ .

When the bobbin counter reaches the "bobbin counter value x 10", the bobbin count complete screen is displayed.

3) Press ❽ to determine the set value and return the sewing machine to the normal sewing state.

4) The current value on the bobbin count- ❼ B er can be checked by keeping

❼ B held pressed for three seconds in the normal sewing state. The current value on the bobbin counter is displayed. Every time the sewing machine has sewn 10 stitches, "1" is added to the current value on the bobbin counter.

When you press switch is

pressed, the sewing machine returns to the normal sewing state.

5) Carry out sewing. When the bobbin counter value becomes "0" (zero), the count complete screen is displayed.

When you press , the current

value on the bobbin counter returns to the value set with "function setting No. P113 Bobbin counter" and the sewing machine returns to the normal sewing state.

– 48 – 4-12. Initialization of function setting data The function setting data that are changed arbitrarily by the customer can be stored in memory. The current function setting data can be restored to the aforementioned data.

1) When you keep held pressed

for three seconds in the normal sewing state, the function setting screen is A B displayed. Refer to "4-6. Function setting" p. 31.

2) When you keep held

pressed for three seconds on the function setting screen, all function setting data are stored in memory and the "SAVE" screen is displayed for a brief second.

3) When you keep held pressed

for six seconds, the data initialization confirmation screen is displayed.

4) When you press ❽ , all of the ❽ current function setting data are initialized to the function setting data to those stored in memory in the aforementioned steps of procedure 1) and 2), and returns the sewing machine to the normal sewing state.

– 49 – 4-13. Password lock

It is possible to lock the operation for setting the functions by keeping held pressed, with the password.

❻ ❼

1) Call the function setting No. J14 referring to referring to "4-6. Function setting" p. 31.

A B

❽

2) Press ❼ to flash the setting itemB . In this state, set a 4-digit password by pressing

❻ .

Write down the password you have set so to remember it.

3) Press ❽ to determine the password and return the sewing machine to the normal sewing state.

❻ ❼

4) If the password is set to a number other than "0000", the password entry screen will be displayed before displaying the function setting screen by

pressing the held pressed for ❽ three seconds.

5) Enter the four-digit password you have set to the [function setting No. J14] using ❼ and

❻ .

6) The function setting screen is displayed by pressing ❽ . On this screen, the functions can be set.

– 50 – 4-14. About the USB

WARNING : The device to be connected to the USB port should have the rated current value or less as shown below. If any device rated current value of which is higher than the rated current value, the main body of the sewing machine or the USB device connected can be damaged or malfunction. Rated current value of the USB port USB port on the electrical box side: Maximum rated current value of 1 A USB port on the operation panel side: Maximum rated current value of 0.5 A

[Insertion position of the USB thumb drive] The USB connectors are equipped on upper section ❶ ❶ of the operation panel and electrical box ❷ . To use a USB thumb drive, remove connector cover ❸ and insert the USB thumb drive into the USB con- ❸ nector. * In the case a USB thumb drive is not used, the USB connector should be protected with connector cover ❸ without exceptions. If dust or the like enters the USB connector, a fail- ure can be caused.

❷

❸

– 51 – 5. ADJUSTMENT OF THE MACHINE HEAD (APPLICATION) 5-1. Needle-to-hook relationship

WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

Adjust the timing between the needle and the hook as follows : 1) Adjusting the needle bar height. Turn the handwheel to bright the needle bar down to the lowest point of its stroke, and loosen setscrew ❶ . ❶ 2) Adjusting the needle bar height. Align marker line (For a DB needle : marker line A, For a DA needle : marker line C) on needle bar ❷ with the bottom end of needle bar lower bushing ❸ , then tighten setscrew ❶ . 3) Position the needle and the hook a. Loosen the three hook setscrews, turn the handwheel in normal rotation and align marker line (For a DB needle : marker line B, For a DA needle : C marker line D) on ascending needle bar ❷ with D the bottom end of needle bar lower bushing ❸ . 4) In this state, align hook blade point ❺ with the A center of needle ❹ . Provide a clearance of 0.04 B to 0.1 mm (reference value) between the needle 0.04 to 0.1 mm and the hook, then securely tighten the three hook setscrews. ❹ ❺ If the clearance between the blade point of hook and the needle is smaller than the specified value, the blade point of hook will be damaged. If the clearance a is larger, stitch skipping will result.

❸

A B ❷

– 52 – 5-2. Adjusting the needle thread presser device

WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

[Feature] The needle thread presser device is able to tuck the needle thread on the wrong side of material as in the case of the conventional wiper device. • Operability around the needle entry point is improved. • Applicability of various kinds of attachments de- signed for use around the needle entry point is improved.

Needle thread presser device

[How to set the needle thread presser device]

Keep thread presser operation enable /

disable switch held pressed to

change over the ON/OFF of the thread presser. When the thread presser device is set to ON, the thread presser icon is displayed on display section C.

Display section C

In the case the memory switch "Reverse-rotation needle-up after thread trimming, p.46" is used, the length of needle thread remaining after thread trimming becomes longer. So, in this case, the needle thread clamp device should be set to "OFF".

– 53 – [Adjusting the remaining length of needle thread] Adjust the length of needle thread remaining at the needle to 35 to 45 mm (for both the S and H types) by turning thread tension No. 1 nut ① . ① B 1) Turn thread tension No. 1 nut clockwise (in A direction A), to shorten the thread length remaining on the needle after thread trimming or ① counterclockwise (in direction B), to lengthen the thread length.

So-called "bird's nest phenomenon" is reduced by shortening the length of needle thread remaining at the needle. In this case, however, the needle thread is likely to slip off the needle eyelet. To reduce slip-off of the needle thread, sewing speed at the beginning of sewing should be reduced.

35 to 45mm

– 54 – [Response to problems occurring at the beginning of sewing] • In the case needle thread breakage occurs when using a thin thread or fragile thread • In the case needle thread is not tucked on the wrong side of material • In the case needle thread breakage occurs when starting sewing from the material end (such as sewing the material with needle thread tucked on the undersurface of material) If any of the aforementioned problems occurs, the presser foot pressure should be reduced to allow the needle thread pinched between the presser foot and the material to be released smoothly. (The recommended presser foot pressure is 30 N (3 kg) or less.) Adjust the presser foot pressure and the sewing speed appropriately to prevent insufficient feed efficiency due to jumping or other faults of the presser foot. After the adjustment, confirm the adjustment result by actu- ally sewing the material. Needle thread breakage can be reduced and the needle thread can be smoothly tucked in to the undersurface of material by lifting the presser foot by a minute amount at the beginning of sewing. (Set the parameter P161 to 1, and adjust the parameters P162, P164 and P165.)

1. The amount of uplift of the presser foot above the throat plate varies according to the material thickness of the item to be sewn and the presser foot pressure. Be sure to check the actual condition before starting sewing. 2. If the adjustment is increased while the presser foot presser is high, the operating noise will become larger. Adjust the adjustment value and the presser foot pressure while visually checking the needle thread condition.

No. Description Setting range Default P161 ON / OFF of the presser lifting operation when clamping the thread is set with the 0-1 0 function setting item. 0: OFF 1: ON P162 Degree of an angle at which the presser foot starts going up when clamping the 0-359 100 thread Degree of an angle at which the presser foot starts going up when clamping the thread is set with function setting item. P164 Setting of the amount of lift of the presser foot when clamping the thread 0-500 50 The amount of lift of the presser foot when clamping the thread is set with this function setting item. P165 Time during which the presser foot goes up when clamping the thread 1-990 20 The time during which the presser foot goes up when clamping the thread is set with this function setting item.

– 55 – 5-3. Adjusting the thread trimmer

WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

❻ B 5-3-1. For checking of the thread trimming cam timing A The purpose of the adjustment of the thread trimming is to bring marker line A on electrical box C cover ❺ to the portion between the colorless marker ❺ dots B and C on handwheel ❻ . 1) Tilt the sewing machine head. 2) Turn handwheel ❻ by hand in the normal direction of rotation until the thread take-up lever goes ❸ ❶ ❹ up slightly below the upper dead point. Press cam follower ❶ with fingers to the left (in direction of E arrow E) to fit roller❷ to in groove C in thread trimming cam ❸ . ❼ D 3) In this state, turn handwheel ❻ in the direction which is opposite to the normal direction of rotation until handwheel ❻ will go no further. (If the handwheel is turned further, it reaches the ❷ position at which cam follower ❶ starts moving.) At this time, adjust so that the marker line A on electrical box cover ❺ is brought to the portion between the colorless marker dots B and C on handwheel ❻ .

5-3-2. Adjustment of the thread trimming cam timing 1) Tilt the sewing machine head. 2) Loosen the screws No.1 and No. 2 of thread trim- ❸ Turn thread trimming cam in the direction of ❼ arrow until the outer periphery of thread trimming ming cam setscrew in the written order. cam groove C comes in contact with roller ❷ and 3) Align marker line A on electrical box cover ❺ stops. At this position, fix thread trimming cam with the colorless marker dot B on handwheel ❻. setscrew ❼ . 4) Pressing cam follower ❶ to the left (in the direc- Correct (F) Wrong (G) tion of arrow E), engage thread trimming cam ❸ with roller ❷ . Then, turn only thread trimming ❷ cam ❸ with fingers in the direction which is opposite to the normal direction of rotation of feed ❷ driving shaft ❹ until it will go no further without turning feed driving shaft ❹ . At this position, tighten the screws No. 1 and No. 2 of thread trim- C C ming cam setscrew ❼ in the written order while pressing thread trimming cam ❸ against roller ❷ .

The alignment point between thread trimming cam ❸ and roller ❷ is position (F) from which cam follower ❶ starts ❹ moving. Position (G) at which you feel that thread trimming cam ❸ comes in contact with roller ❷ for the first time ❷ C during adjustment is not the correct alignment position. ❸ * Be sure to correct the thread trimming Illustration as observed from D (right side face) cam timing carefully since it largely affects the loop spreading timing.

– 56 – 5-3-3. Checking of the knife unit WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

1) Check to make sure that the power switch is in ❶ the OFF state. Remove the gauge (presser foot, throat plate and feed dog) from around the needle. 2) In the standby state of loop spreading knife ❶ , the distance from center of needle A to the tip of loop spreading knife ❶ is 5 to 6 mm.

Be aware that, if the distance between loop spreading knife ❶ and center of needle A is reduced, thread loop is likely ❷ to interfere with loop spreading knife ❶ .

Standby state of the knife * Refer to "5-3-4. Adjustment of the knife unit" p. 58 for how to adjust it. A 3) The purpose of adjustment of the aligning posi- 5 to 6 mm tion of loop spreading knife ❶ and thread trim- ❶ ming knife ❷ (far end of the hole in loop spread- ❷ ing knife ❶ and the tip of thread trimming knife ❷) is to align the aforementioned aligning position with center of needle A.

Be aware that, if the aligning position of ❶ the loop spreading knife and the thread trimming knife does not align with center of needle A, the length of thread remaining on the material after thread trimming will be longer.

4) The amount of engagement between loop spreading knife ❶ and thread trimming knife ❷ is 2 to 2.5 mm (H type : 2.5 to 3 mm) as measured ❷ Aligning state of salient portion of loop spreading from center of needle A. knife and thread trimming knife ❶ Be aware that, if the amount of engagement between them is insufficient, faulty Far end of the hole in ❷ thread trimming can occur. loop spreading knife ❶ aligns with the tip of thread trimming knife ❷ * Refer to "5-3-4. Adjustment of the knife unit" p. 58 for how to adjust it. A In the case of using a thread that is likely to cause unstable thread loop formation, the needle thread may be trimmed extremely short when thread trimming is carried out at a position where no ❶ material is present. ❷ In this case, correct the aforementioned 2 to 2.5 mm problem by increasing the thread take- A (H type : 2.5 to 3 mm) up spring stroke to a value that is larger State of engagement of knife than the standard value.

– 57 – 5-3-4. Adjustment of the knife unit WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

1) Check to make sure that the power switch is in the OFF state. Remove the gauge (presser foot, throat plate and feed dog) from around the needle. 2) Tilt the sewing machine head. 3) Loosen loop spreading knife eccentric pin setscrews ❷ (two pieces). Turn loop spreading knife eccentric pin ❶ with a flat-blade screwdriver to finely adjust the rotational-direction position of loop spreading knife ❸ . 4) After the adjustment, tighten loop spreading knife eccentric pin setscrews ❷ (two pieces).

Position of marker dot A on loop ❶ spreading knife eccentric pin ❶ should A ❷ be adjusted only from the operator's side.

❸

– 58 – 5-4. Adjusting the main shaft stop position

If the position of the marker line (blue) on the handwheel is too far from the position of the marker line (blue) on the cover after thread trimming, machine head angle should be adjusted following the steps of procedure described below.

❻ ❼

1) The function setting screen is displayed

by keeping held pressed for three seconds on the normal sewing A state. ❽ 2) Press ❼ to flash function

setting No. A on and off. In this state,

press ❻ to select parameter P72. ❶ 3) Turn handwheel in the normal direction of rotation to align marker line A on A B the electrical box cover with marker line B on the handwheel.

4) Press ❽ to determine the set-

ting.

5) Press to return the sewing

machine to the sewing state.

– 59 – 5-5. Grease shortage warning 5-5-1. Grease shortage warning

When the time of maintenance for adding the grease, "E220 Grease shortage warning" error is displayed for three seconds after turning the power ON. In this state, however, the sewing machine can be used for a certain period time.

Once E220 error is displayed, be sure to replenish the sewing machine with grease without exceptions.

* To reset the error (to clear n15), refer to "5-5-3. How to reset the grease shortage error" p. 61.

5-5-2. Grease shortage error

If the error E220 is not reset, "E221 Grease shortage error" will be continuously displayed. If this state continues, the sewing machine operation will be disabled. To prevent this, be sure to reset the error (to clear n15) after carrying out the maintenance for replenishing the sewing machine with grease.

* To reset the error (to clear n15), refer to "5-5-3. How to reset the grease shortage error" p. 61.

– 60 – 5-5-3. How to reset the grease shortage error

❻ 1) Turn ON the power to the sewing

machine while keeping held

pressed. A B Then, the function setting screen is displayed. A shows the function setting number, and B shows the set value for the function setting number.

2) While the function setting number (A) is flashing on and off, press switch ❻ to select the func-

tion setting No. n15.

3) Press to clear the set value (B) to "0" (zero).

* The grease shortage error is reset by carrying out this operation.

4) Press to return the sewing machine to the normal sewing state.

– 61 – 5-6. Disposal of batteries

The operation panel has a built-in battery in order to operate the clock even when the power is turned OFF. Be sure to dispose of the battery following the local laws and regulations.

[How to remove the battery] 1) Remove panel ❶ from the main body ❸ ❷ ❷ of sewing machine. 2) Loosen screw ❷ from the rear surface of the operation panel. Detach case ❸.

❷ ❷

3) ❹ is the battery for clock. Type number: CR2450 4) Pull out the connector in the direction of A. Detach the whole main body of battery together with its case from the PCB. (The battery is secure on the PCB with double-faced adhesive tape.)

❹ Type number: CR2450 A

– 62 – 6. CARE

Perform the maintenance below every day for longer use of your machine.

6-1. Cleaning

WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

1) Remove needle ❶ , presser foot ❷ and throat plate ❸ .

❶ ❷ ❸

2) Remove dust adhered to feed dog ❹ and thread ❹ trimmer unit ❺ with a soft brush or cloth. ❺

3) Tilt the machine head and wipe out the dirt of bobbin case and the like with soft cloth, and confirm that there is no scratch. Wipe out with the cloth dust and hook oil drained in the under cover near the hook.

– 63 – 6-2. Applying grease

WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

1. When the machine needs replenishment of grease, an alarm sounds. Once the alarm sounds, replenish grease. In the case the machine is used under harsh environment, it is recommended to replenish grease once a year for ensuring effective greasing. ❶ 2. Do not apply oil to the sections which are lubricated with grease. 3. Be aware that grease can leak from the thread take-up cover and needle bar if the amount of grease is excessive. 4. Be sure to use JUKI GREASE A TUBE ❶ (part number : 40006323).

6-3. Applying grease to the needle bar lower bushing

WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine.

Carry out greasing with the needle bar installed.

1) Remove the face plate. 2) Remove needle bar lower bushing greasing screw ❷ (only for the DDL-8000A-PMS) with a hexagonal wrench key.

❷

3) Remove the cap of exclusive grease tube ❶ . Insert its tip into the oil hole and replenish grease from exclusive grease tube ❶ . At this time, add grease until it overflows the oil hole. 4) Push overflowing exclusive grease with the oil filling screw into the oil hole. 5) Wipe the excess of grease off the area around the oil hole. ❶

– 64 – 7. LIST OF ERROR CODES

Error Description How to correct number E001 High-voltage error (320 V or more) Turn the power OFF. Check the supply voltage. E002 Low-voltage error (170 V or less) Turn the power OFF. Check the supply voltage. E003 CPU communication fault Turn the power OFF. Check the connection of the connector E003P to the operation panel and the cable. E005 Pedal connection fault Turn the power OFF. Check the connection of the connector to the pedal and the cable. E007 Main shaft rotation fault Check whether the main shaft motor is locked by turning the pulley. Check the connection encoder cable and motor power cable to the connectors. Check whether the supply voltage is normal. Check whether the sewing speed is set extremely high. E009 Encoder Z-phase detection fault Turn the power OFF. Check the connection of the motor E011 encoder cable to the connector. E014 Encoder AB-phase detection fault Turn the power OFF. Check the connection of the motor encoder cable to the connector. E015 Main shaft motor overcurrent error Turn the power OFF. Then, re-turn the power ON. E017 Machine head tilting error Raise the machine head. Then, turn the power OFF and return the power ON. Check whether the machine head tilt switch has broken. E020 Main shaft rotation fault Turn the power OFF. Check the connection of the main shaft motor encoder cable and motor power cable to the connectors. E030 Communication fault between the main Turn the power OFF. Check whether the presser motor is CPU and the presser motor CPU locked. Check the connection of the presser motor to the connector. E031 Presser motor overcurrent error Turn the power OFF. Check whether the presser motor is locked. Check the connection of the presser motor to the connector. E032 Presser motor origin retrieval error Turn the power OFF. Check whether the presser motor is locked. Check the connection of the presser motor and origin sensor to the connectors. E040 Crystal oscillator fault Turn the power OFF. Change the panel PCB with a new one. E220 Grease shortage warning Carry out maintenance for replenishing the grease. Then, reset the error (to clear n15). Refer to "5-5. Grease shortage warning" p. 60. E221 Grease-shortage error Carry out maintenance for replenishing the grease. Then, reset the error (to clear n15). Refer to "5-5. Grease shortage warning" p. 60.

– 65 –